Systems and methods for a disconnect switch assembly having a reversible fuse support block

ABSTRACT

A reversible fuse support block includes a molding, a terminal, and a fuser interface. The molding may be installed within a housing in a first position and a second position, wherein the second position is rotated 180 degrees relative to the first position. The terminal couples to the molding and includes a plurality of apertures disposed in a pattern. The fuse interface receives a first end of a fuse. The fuse interface couples to the terminal in a first arrangement and a second arrangement such that when the fuse interface is installed in the first arrangement and the molding is installed in the first position, the fuse interface is disposed in substantially the same position relative to a corresponding fuse interface on a fuse support block as when the fuse interface is installed in the second arrangement and the molding is installed in the second position.

BACKGROUND

The present disclosure relates generally to disconnect switchassemblies. More specifically, the present disclosure relates todisconnect switch assemblies having fuse support blocks that can beinstalled in multiple configurations.

Industrial automation systems may be used to provide automated controlof one or more actuators. Specifically, a motor control center mayreceive power from a power source and output a conditioned power signalto an actuator to control movement of the actuator. In some embodiments,the motor control center may include an industrial automation motorstarter and a disconnect switch to disconnect the power source from theindustrial automation motor starter and the actuator. With theindustrial automation motor starter and the actuator disconnected fromthe power source, maintenance, diagnostics, repair work, etc. may beperformed without the risk of the industrial automation motor starterand/or the actuator unexpectedly powering up. In some applications,space may be at a premium. Accordingly, it may be desirable to reduce orminimize a footprint of the disconnect switch assembly.

BRIEF DESCRIPTION

In one embodiment, a reversible fuse support block includes a molding, aterminal, and a fuse interface. The molding may be installed within ahousing in a first position and a second position, wherein the secondposition is rotated 180 degrees relative to the first position. Theterminal couples to the molding and includes a plurality of aperturesdisposed in a pattern. The fuse interface receives a first end of afuse. The fuse interface couples to the terminal in a first arrangementand a second arrangement such that when the fuse interface is installedin the first arrangement and the molding is installed in the firstposition, the fuse interface is disposed in substantially the sameposition relative to a corresponding fuse interface on a fuse supportblock as when the fuse interface is installed in the second arrangementand the molding is installed in the second position.

In another embodiment, a method of installing a fuse support blockincludes coupling a terminal to a molding, coupling a fuse interface tothe terminal, and installing the molding in a housing. The molding canbe installed within the housing in a first position and a secondposition. The terminal includes a plurality of apertures disposed in apattern. The fuse interface receives a first end of a fuse. The fuseinterface can couple to the terminal in a first arrangement and a secondarrangement such that when the fuse interface is installed in the firstarrangement and the molding is installed in the first position, the fuseinterface is disposed in substantially the same position relative to acorresponding fuse interface on a fuse support block as when the fuseinterface is installed in the second arrangement and the molding isinstalled in the second position.

In yet another embodiment, an industrial automation system includes apower supply, an industrial automation motor starter that receives powerfrom the power supply, and a disconnect switch assembly thatelectrically couples the power supply to the industrial automation motorstarter. The disconnect switch assembly includes a housing, a fuseblock, and a reversible fuse support block. The fuse block is disposedwithin the housing and includes a first fuse interface that receives afirst end of a fuse. The reversible fuse support block is disposedwithin the housing and includes a molding, a terminal, and a fuserinterface. The molding may be installed within the housing in a firstposition and a second position, wherein the second position is rotated180 degrees relative to the first position. The terminal couples to themolding and includes a plurality of apertures disposed in a pattern. Thefuse interface receives a second end of the fuse. The fuse interfacecouples to the terminal in a first arrangement and a second arrangementsuch that when the fuse interface is installed in the first arrangementand the molding is installed in the first position, the fuse interfaceis disposed in substantially the same position relative to the firstfuse interface as when the fuse interface is installed in the secondarrangement and the molding is installed in the second position.

DRAWINGS

These and other features, aspects, and advantages of the presentembodiments will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 illustrates a perspective view of an industrial automationsystem, including a motor control center having a disconnect switchassembly and an industrial automation motor starter, in accordance withembodiments presented herein;

FIG. 2 illustrates a block diagram of example component parts of themotor control center of FIG. 1, in accordance with embodiments presentedherein;

FIG. 3 illustrates a perspective view of an embodiment of the disconnectswitch assembly of the industrial automation system shown in FIGS. 1 and2 installed in a first configuration, in accordance with embodimentspresented herein;

FIG. 4 illustrates a perspective view of an embodiment of the disconnectswitch assembly shown in FIG. 3 installed in an second configuration, inaccordance with embodiments presented herein;

FIG. 5 illustrates an exploded perspective view of a 30 Amp fuse supportblock of the disconnect switch assembly shown in FIGS. 3 and 4, inaccordance with embodiments presented herein;

FIG. 6 illustrates a perspective view of the 30 Amp fuse support blockshown in FIG. 5 installed in the first configuration, in accordance withembodiments presented herein;

FIG. 7 illustrates a perspective view of the 30 Amp fuse support blockshown in FIGS. 5 and 6 installed in the second configuration, inaccordance with embodiments presented herein;

FIG. 8 illustrates an exploded perspective view of a 60 Amp fuse supportblock of the disconnect switch assembly shown in FIGS. 3 and 4, inaccordance with embodiments presented herein;

FIG. 9 illustrates a perspective view of the 60 Amp fuse support blockshown in FIG. 8 installed in a first configuration, in accordance withembodiments presented herein;

FIG. 10 illustrates a perspective view of the 60 Amp fuse support blockshown in FIGS. 8 and 9 installed in a second configuration, inaccordance with embodiments presented herein;

FIG. 11 illustrates an exploded perspective view of a 100 Amp fusesupport block of the disconnect switch assembly shown in FIGS. 3 and 4,in accordance with embodiments presented herein;

FIG. 12 illustrates a perspective view of the 100 Amp fuse support blockshown in FIG. 11 installed in a first configuration, in accordance withembodiments presented herein;

FIG. 13 illustrates a perspective view of the 100 Amp fuse support blockshown in FIGS. 11 and 12 installed in a second configuration, inaccordance with embodiments presented herein; and

FIG. 14 illustrates a flow chart of a process for assembling andinstalling the fuse support block of the disconnect switch assembly, inaccordance with embodiments presented herein.

DETAILED DESCRIPTION

One or more specific embodiments will be described below. In an effortto provide a concise description of these embodiments, not all featuresof an actual implementation are described in the specification. Itshould be appreciated that in the development of any such actualimplementation, as in any engineering or design project, numerousimplementation-specific decisions must be made to achieve thedevelopers' specific goals, such as compliance with system-related andbusiness-related constraints, which may vary from one implementation toanother. Moreover, it should be appreciated that such a developmenteffort might be complex and time consuming, but would nevertheless be aroutine undertaking of design, fabrication, and manufacture for those ofordinary skill having the benefit of this disclosure.

When introducing elements of various embodiments of the presentinvention, the articles “a,” “an,” “the,” and “said” are intended tomean that there are one or more of the elements. The terms “comprising,”“including,” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

An industrial automation system may utilize a motor control center,including an industrial automation motor starter, to receive power froma power source and output a conditioned power signal to an actuator tocontrol movement of the actuator. A disconnect switch assembly disposedwithin the motor control center may electrically couple the power sourceto the industrial automation motor starter and disconnect the powersource from the industrial automation motor starter and the actuator.After the power source is disconnected from the industrial automationmotor starter, maintenance, diagnostics, repair work, etc. may beperformed without the risk of the industrial automation motor starterand/or the actuator unexpectedly powering up. In some applications,physical space may be limited in a housing or enclosure of the motorcontrol center. For example, a customer or designer of the industrialautomation system may wish to reduce the footprint of the disconnectswitch assembly to design a smaller housing, or to fit the disconnectswitch assembly into a fixed-size housing that is smaller than waspreviously possible.

The disclosed techniques include a reversible fuse support block for adisconnect switch assembly that can be mounted in a first configurationhaving a first-sized footprint (e.g., vertical and horizontaldimensions), or a second configuration having a reduced footprint.Specifically, the fuse support block includes a molding having two setsof mounting holes that allow the molding to be installed within thehousing in two different positions (e.g., for first configuration andsecond configuration). The fuse support block includes one or moreterminals, each having a pattern of apertures, which mount to themolding. One or more fuse interfaces couple to respective terminals intwo possible positions, a first position for the first configuration,and a second position for the second configuration. When the fuseinterfaces are installed in the first position and the molding isinstalled in the first position, the fuse interfaces are disposed insubstantially the same position relative to corresponding fuseinterfaces on a fuse support block as when the fuse interfaces areinstalled in the second position and the molding is installed in thesecond position. Accordingly, when the fuse support block is installedin the second position, electrical lines coupling the fuse support blockto the power source extend from the fuse support block underneath thefuses rather than extending outward from the side of the fuse supportblock opposite the fuses. Thus, the second configuration reduces thefootprint of the disconnect switch assembly relative to the firstconfiguration.

By way of introduction, FIG. 1 is a perspective view of an industrialautomation system 10, including an industrial automation motor starter12, a disconnect switch 14, a control system 16, and a motor 18. Asshown, the industrial automation system 10 may also include, or becoupled to, a power source 20. In the instant embodiment, the industrialautomation motor starter 12, the disconnect switch 14, and the controlsystem 16 are disposed in a motor control center 22. The motor controlcenter may include a cabinet or some other enclosure for housing variouscomponents of the industrial automation system 10, such as theindustrial automation motor starter 12, the disconnect switch 14, andthe control system 16. The industrial automation motor starter 12 mayinclude, for example, an across the line starter or direct on line (DOL)starter, a solid state motor starter (e.g., a motor drive or a reducedvoltage soft starter), etc. In some embodiments, the disconnect switch14 may include its own disconnect switch housing 24 within the motorcontrol center 22. However, embodiments are also envisaged in which theindustrial automation motor starter 12 and the disconnect switch 14 aredisposed in different housings or enclosures. The motor control center22 may include or receive a user interface 26, such as a human machineinterface (HMI) 26.

As described further below with regard to FIG. 2, the industrialautomation motor starter 12 may be adapted to receive three-phasealternating-current (AC) power from the power supply 20 and to convert afixed frequency AC input power from the power supply 20 to controlledfrequency AC output power that may be applied to the motor 18, or othersuitable electrical component. The power supply 20 may include agenerator or an external power grid. A variety of components or devicesmay be disposed within the industrial automation motor starter 12 andmay be used in the operation and control of a load such as the motor 18.

Keeping this in mind, FIG. 2 illustrates a block diagram of theindustrial motor control center 22 and provides additional detailsregarding the make-up of the motor control center 22. As illustrated,the industrial automation motor starter 12 may include a rectifier 100that receives a constant frequency three-phase AC voltage waveform fromthe power supply 20. The rectifier 100 may perform full waverectification of the three-phase AC voltage waveform, outputting adirect current (DC) voltage to an inverter module 102. Although the ACpower supply 20 has been described above as providing a constantfrequency three-phase AC voltage waveform, it should be noted that theAC power supply 20 is not limited to providing a three-phase AC voltagewaveform. Instead, it should be understood that the AC power supply 20may also provide different waveforms such as a six-phase AC voltagewaveform or the like.

The inverter module 102 may accept the positive and negative lines ofthe DC voltage from the rectifier 100 and may output a discretizedthree-phase AC voltage waveform at a desired frequency, independent ofthe frequency of AC power supply 20. Driver circuitry 104 may providethe inverter module 102 with appropriate signals, enabling the invertermodule 102 to output the AC voltage waveform. The resulting AC voltagewaveform may thereafter drive a load, such as the motor 18.

The control system 16 may be coupled to the driver circuitry 104 and maybe programmed to provide signals to the driver circuitry 104 for drivingthe motor 18. In certain embodiments, the control system 16 may beprogrammed according to a specific configuration desired for aparticular application. For example, the control system 16 may beprogrammed to respond to external inputs, such as reference signals,alarms, command/status signals, etc. The external inputs may originatefrom one or more relays or other electronic devices. The programming ofthe control system 16 may be accomplished through software configurationor firmware code that may be loaded onto an internal memory of thecontrol system 16 or programmed via the user interface 26 of theindustrial automation motor starter 12. The firmware of the controlsystem 16 may respond to a defined set of operating parameters. Thesettings of the various operating parameters determine the operatingcharacteristics of the industrial automation motor starter 12. Forexample, various operating parameters may determine the speed or torqueof the motor 18 or may determine how the industrial automation motorstarter 12 responds to the various external inputs. As such, theoperating parameters may be used to map control variables within theindustrial automation motor starter 12 or to control other devicescommunicatively coupled to the industrial automation motor starter 12.These variables may include, for example, speed presets, feedback typesand values, computational gains and variables, algorithm adjustments,status and feedback variables, and programmable logic controller (PLC)like control programming.

The industrial automation motor starter 12 and the motor 18 may alsoinclude one or more sensors 106 for detecting operating temperatures,voltages, currents, etc. With feedback data from the sensors 106, thecontrol system 16 may keep detailed track of the various conditionsunder which the inverter module 102 may be operating. For example, thefeedback data may include conditions such as actual motor speed, voltagefrequency, power quality, alarm conditions, etc. The feedback data maythen be used to control other devices such as the disconnect switch 14,which is described in greater detail below.

In some embodiments, the industrial automation motor starter 12 may becommunicatively coupled to one or more peripheral devices. For example,in one embodiment, the control system 16 may be communicatively coupledto a remote system 108, which may be used to control the industrialautomation motor starter 12, the motor 18, or the disconnect switch 14via the control system 16 from a remote location away from where theindustrial automation system 10 is located. In certain embodiments, thecontrol system 16 may be communicatively coupled to the remote system108 via a wireless network, a local area network, the Internet, or thelike. However, it should be noted that the control system 16 may becommunicatively coupled to the remote system 108 via a hard-wiredconnection, such as an Ethernet connection or the like.

To isolate the industrial automation motor starter 12 from the AC powersupply 20, the disconnect switch 14 may be opened, thereby removing theinput AC voltage from the industrial automation motor starter 12. Assuch, the disconnect switch 14 may include mechanical components thatenable one or more poles of the disconnect switch 14 to open (i.e.,break a circuit) and close. In this way, the disconnect switch 14 mayprotect the industrial automation motor starter 12, the motor 18, andother downstream devices when the power from the AC power supply 20 maycause damage to the industrial automation system 10. For example, thedisconnect switch 14 may open when the AC voltage from the AC powersupply 20 is unbalanced, experiencing a fault, experiencingunder-voltage or over-voltage conditions, increased levels of harmonics,or the like. In certain embodiments, the disconnect switch 14 may be acircuit breaker, a molded case switch, or the like. The disconnectswitch 14 may be a three-pole switch that may disconnect the three-phaseAC power supply 20 from the industrial automation motor starter 12.However, it should be noted that the disconnect switch 14 is not limitedto a three-pole switch and may include any number of poles.

FIG. 3 is a perspective view of an embodiment of a disconnect switchassembly 200, which includes the disconnect switch 14 of the industrialautomation system 10 shown in FIGS. 1 and 2. The disconnect switchassembly 200 includes a fuse block 202, which houses the disconnectswitch 14, and a fuse support block 204 installed in a firstconfiguration. As shown, the fuse block 202 and the fuse support block204 are coupled to the housing 24 and spaced apart from one another.First, second, and third fuses 206 extend from the fuse support block204 to the fuse block 202. The fuses 206 are represented in FIG. 3 bydotted lines for clarity. First, second, and third electrical lines 208,one for each phase of power, deliver power signals from the power supply20 to first, second, and third respective terminals 210 of the fusesupport block 204. The power signal for each phase conducts through therespective fuse 206 to the fuse block 202. If the current through one ofthe fuses 206 exceeds a threshold value, a conductive element in thefuse 206 opens, breaking the circuit and preventing the conduction ofelectricity through the fuse 206. The fuse block 202 includes thedisconnect switch 14, which may be a three-pole switch that connects anddisconnects the industrial automation motor starter 12 from the powersupply 20. As previously described, the disconnect switch 14 may bemanually actuated, actuated by the control system 16, or actuated insome other fashion. When the disconnect switch 14 is closed, the powersignal conducts through the fuse block 202 and to the industrialautomation motor starter 12 via one or more electrical lines 212. Whenthe disconnect switch 14 is open, the power signal does not conductthrough the disconnect switch assembly 200.

As shown in FIG. 3, the fuse block 202 and the fuse support block 204each include a plurality of fuse interfaces 214. The fuse interfaces 214may provide a physical coupling between one end of the fuse 206 and thefuse block 202 or the fuse support block 204, capturing the fuse 206, aswell as an electrical coupling between the fuse 206 and the fuse block202 or the fuse support block 204. As described in more detail below,the fuse interface 214 may be a clip, a V-block, or some other kind ofinterface. Further, in some embodiments, blade style fuses 206 may bemounted directly to the terminals 210 without using V-blocks.

Further, in some embodiments, the fuse block 202 and/or the fuse supportblock 204 may include fuse insulation 216 disposed about one or more ofthe fuse interfaces 214 to insulate the fuses 206 from one another andto achieve appropriate creepage and clearance distances. In the instantembodiment, the fuse insulation 216 is shown disposed about the centralterminal of the fuse block 202, however, it should be understood thatany of the terminals of the fuse block 202 or the fuse support block 204may be outfitted with fuse insulation 216.

The embodiment of the disconnect switch assembly 200 shown in FIG. 3 isfor a 30 Amp disconnect switch assembly 200. However, it should beunderstood that similar disconnect switch assemblies 200 designed forother amperages are also envisaged. For example, a 60 Amp disconnectswitch assembly 200 is described below with regard to FIGS. 8-10 and a100 Amp disconnect switch assembly 200 is described below with regard toFIGS. 11-13. However, the 30 Amp, 60 Amp, and 100 Amp embodimentsdescribed herein are merely examples and not intended to be limiting.Accordingly, the disclosed techniques may be extended to disconnectswitch assemblies 200 rated for any suitable amperage rating other than30 Amps, 60 Amps, or 100 Amps.

As shown in FIG. 3, when the fuse support block 204 is installed in thefirst configuration, the electrical lines 208 couple to the fuse supportblock 204 on a first side of the fuse support block 204 that faces awayfrom the fuse block 202, such that the electrical lines 208 extendoutward from the fuse support block 204 opposite the direction of thefuse block 202. However, where space is limited, a user or designer ofthe industrial automation system 10 may wish to minimize the size and/orfootprint of the disconnect switch assembly 200 and/or its housing 24.Alternatively, the user or designer of the industrial automation system10 may wish to fit the disconnect switch assembly 200 into a fixed sizedhousing 24 in which the disconnect switch assembly 200 with the fusesupport block 204 installed in the first configuration, as shown in FIG.3, would not fit. Accordingly, the fuse support block 204 may bedesigned to be reversible such that the fuse support block 204 may bereconfigured with the same parts and installed in a second position suchthat the electrical lines 208 couple to the fuse support block 204 on aside of the fuse support block 204 that faces the fuse block 202, suchthat the electrical lines 208 extend outward from the fuse support block204 toward the fuse block 202, thereby preserving space occupied by theelectrical lines 208 extending outward from the fuse support block 204,away from fuse block 202, when installed in the first configuration.

Specifically, the fuse support block 204 includes a molding 218, whichacts as a base for the fuse support block 204. The molding 218 may be asingle part or a multi-part component that is manufactured (e.g.,molded, cast, machined, etc.) from a non-conductive material. Themolding 218 may include a first set of mounting holes 220 for mountingthe molding 218 to the housing 24 in the first configuration and asecond set of mounting holes 220 for mounting the molding 218 to thehousing 24 in the second configuration.

The fuse support block 204 also includes the first, second, and thirdterminals 210, one for each phase of power. The terminals 210 aregenerally rectangular components made from a conductive material andthat provide an electrical connection between the electrical lines 208and the fuse interfaces 214. As described in more detail below, theterminals 210 may include a pattern of holes and/or apertures tofacilitate coupling to the molding 218, the fuse interfaces 214, and oneor more connection points 222 that couple the electrical lines 208 tothe fuse support block 204. The hole pattern in each of the terminals210 allows the respective fuse interfaces 214 to be mounted to theterminals 210 and the molding 218 in two different positions,approximately 180 degrees offset from one another, one corresponding tothe first configuration and one corresponding to the secondconfiguration. That is, the two different fuse interface 214 mountingpositions allow the components of the fuse support block 204 other thanthe fuse interfaces 214 (e.g., the molding 218, the terminals 210, andthe connection points 222) to be mounted in the first configuration orthe second configuration, approximately 180 degrees offset from oneanother. The fuse interfaces 214 are in approximately the same positionrelative to the respective fuse interfaces 214 of the fuse block 202 inboth configurations. For example, a distance 224 between the fuseinterfaces 214 of the fuse block 202 and the fuse interfaces 214 of thefuse support block 204 may be the same when the fuse support block 204is installed in either the first configuration or the secondconfiguration. However, a distance 226 between the fuse block 202 andthe fuse support block 204 may be different when the fuse support block204 is installed in the first configuration and when the fuse supportblock 204 is installed in the second configuration.

FIG. 4 is a perspective view of an embodiment of the disconnect switchassembly 200 of FIG. 3, with the fuse support block 204 installed in thesecond configuration. As illustrated in in FIG. 4, all of the componentsof the fuse support block 204 except for the fuse interfaces 214 (e.g.,the molding 218, the terminals 210, and the connection points 222) havebeen rotated 180 degrees and mounted to the housing 24, via the mountingholes 220, corresponding to the second configuration. Accordingly, theelectrical lines 208 may couple to the fuse support block 204 at theside that faces the fuse block 202, such that the electrical lines 208extend from the fuse support block 204 substantially outward toward thefuse block 202, beneath the fuses 206. Further, though the distance 226between the fuse block 202 and the fuse support block 204 is smaller inthe second configuration than in the first configuration, the distance224 between the fuse interfaces 214 of the fuse block 202 and the fuseinterfaces 214 of the fuse support block 204 is substantially the samein the second configuration as it is in the first configuration.Accordingly, because the electrical lines 208 run between the fuse block202 and the fuse support block 204, beneath the fuses 206, and the fusesupport block 204 is mounted closer to the fuse block 202, the overallfootprint of the disconnect switch assembly 200 is smaller in the secondconfiguration than in the first configuration. Thus, the disconnectswitch assembly 200 may be housed in a smaller housing 24 than waspreviously possible. For example, mounting the fuse support block 204 inthe second configuration may allow a user or designer of the industrialautomation system 10 to reduce the size of the housing 24, or utilize afixed sized housing 24 of a smaller size than was previously possible.

FIG. 5 is an exploded perspective view of the 30 Amp fuse support block204 of FIGS. 3 and 4. As illustrated, the fuse support block 204includes the molding 218, three terminals 210, three fuse interfaces214, and three connection points 222. In the instant embodiment, themolding 218 is made of a single part, molded from a non-conductivematerial, such as a polymer. However, embodiments are envisaged in whichthe molding 218 includes multiple parts, is made by some other process(e.g., casting, machining, etc.), is made of some other material, or acombination thereof. As previously discussed, the fuse support block 204includes one terminal 210 per phase of power. Accordingly, because theillustrated embodiment is designed for use with a 3-phase power source,the molding includes first, second, and third blocks 300, one for eachphase of power. The blocks 300 are coupled to one another by bridges 302disposed between the blocks 300. Each block 300 may include a recess 304dimensioned to receive one of the terminals 210 and an aperture 306(e.g., through hole) through which a fastener 308 (e.g., bolt) mayextend to couple the terminal 210 to the block 300. Each of the bridges302 may include a first aperture 310 and a second aperture 312. In someembodiments, the first aperture 310 may receive a fastener to couple themolding 218 to the housing 24 in the first configuration and the secondaperture 312 may receive the fastener to couple the molding 218 to thehousing 24 in the second configuration. In other embodiments, the firstaperture 310 may receive the fastener to couple the molding 218 to thehousing 24 in the second configuration and the second aperture 312 mayreceive the fastener to couple the molding 218 to the housing 24 in thefirst configuration.

Each terminal 210 includes a pattern of apertures to facilitate couplingthe terminal 210 to its respective block 300, coupling the connectionpoint 222 and the electrical line to the terminal 210, and coupling thefuse interface 214 to the terminal 210. For example, each of theterminals 210 in FIG. 5 includes a first primary aperture 314, a secondprimary aperture 316, a third primary aperture 318, a first auxiliaryaperture 320, and a second auxiliary aperture 322. The first primaryaperture 314 may receive a fastener 324 that extends through theconnection point 222 to couple the connection point 222 and theelectrical line 208 to the terminal 210 and establish an electricalconnection between the electrical line 208 and the terminal 210. In someembodiments, the terminal 210 may include notches 326 on one or bothsides of the first primary aperture 314, such that one or more legs 327of the connection point 222 may extend around the edge of the terminal210, between the terminal 210 and the block 300. The second primaryaperture 316 may receive the fastener 308 extending through the aperture306 in the block 300 to couple the terminal 210 to the block 300. Thethird primary aperture 318 may receive a fastener 328 extending throughan aperture 330 in the fuse interface 214 to couple the fuse interface214 to the terminal 210. The first and second auxiliary apertures 320,322 are may interface with detents or protrusions 332 on the fuseinterface 214. The protrusions 332 may engage with the first and secondauxiliary apertures 320, 322 to prevent the fuse interface 214 fromrotating relative to the terminal 210 and/or to key the fuse interface214 into the desired position.

The fuse interfaces 214 shown in FIG. 5 are a clip-type interface, inwhich the fuse 206 snaps into the fuse interface 214. In someembodiments, the fuse interfaces 214 may include slots 334 thatinterface with an annular lip of the fuse 206 to position the fuse 206axially along an axis of the fuse 206.

FIG. 6 is a perspective view of the 30 Amp fuse support block 204 in thefirst configuration, without the fuse interfaces 214 shown for the sakeof clarity. As shown, the terminals 210 are coupled to the molding 218via the second primary aperture 316 of each terminal 210. The connectionpoints 222 are then coupled to the respective terminal 210 via thefasteners 324 to couple the electrical lines 208 (not shown) to therespective terminals 210. The fuse support block 204 may be coupled tothe housing 24 via fasteners extending through the first apertures 310of the molding 218 and then engaging with the housing 24. As waspreviously shown in and described with regard to FIG. 3, when the fusesupport block 204 is installed in the first configuration, theelectrical lines 208 (not shown) extend outward from the fuse supportblock 204, opposite the direction of the fuse block 202 (not shown).

FIG. 7 is a perspective view of the 30 Amp fuse support block 204 in thesecond configuration, without the fuse interfaces 214 shown for the sakeof clarity. Unlike the first configuration shown in FIG. 6, the fusesupport block 204 may be coupled to the housing 24 via fastenersextending through the second apertures 312 of the molding 218 and thenengaging with the housing 24. As was previously shown in and describedwith regard to FIG. 4, when the fuse support block 204 is installed inthe second configuration, the electrical lines 208 (not shown) couple tothe fuse support block 204 at the side that faces the fuse block 202(not shown), such that the electrical lines 208 (not shown) extend fromthe fuse support block 204 substantially outward toward the fuse block202, beneath the fuses 206, thus reducing the footprint of thedisconnect switch assembly 200 relative to the first configuration.

FIG. 8 is an exploded perspective view of a 60 Amp fuse support block204, which is an alternate embodiment of the 30 Amp fuse support blockshown in FIG. 5. As with the 30 Amp embodiment, the 60 Amp fuse supportblock 204 includes the molding 218, three terminals 210, and three fuseinterfaces 214. As shown in FIG. 8, the terminals 210 do not include thenotches 326 shown in FIG. 5. Additionally, the 60 Amp fuse support block204 does not include the connection points 222 shown in FIG. 5, as theelectrical lines couple directly to the terminals 210 via ring lugs andfasteners. The 30 Amp and 60 Amp fuse support block 204 designs mayshare a common molding 218 design. Accordingly, the molding 218 for the60 Amp fuse support block 204 may be made of a single part molded from anon-conductive material, such as a polymer. As with the 30 Amp fusesupport block 204, the 60 Amp fuse support block 204 includes threeterminals 210, one for each phase of power. As such, the molding 218includes the first, second, and third blocks 300, which are coupled toone another by the bridges 302 disposed between the blocks 300. Each ofthe blocks 300 may include the recess 304 dimensioned to receive therespective terminal 210 and the aperture 306 (e.g., through hole)through which the fastener 308 (e.g., bolt) may extend to couple theterminal 210 to the block 300. Each of the bridges 302 includes thefirst aperture 310 and the second aperture 312, which may be used tomount the fuse support block 204 to the housing 24 in the first andsecond configurations, respectively.

As with the 30 Amp fuse support block 204, each terminal 210 includesthe pattern of apertures to facilitate coupling the molding 218, thefuse interface 214, and the electrical line to the terminal 210 (e.g.,via a ring lug and a fastener). As with the terminals 210 for the 30 Ampfuse support block 204, each of the terminals 210 for the 60 Amp fusesupport block 204 include the first primary aperture 314, the secondprimary aperture 316, the third primary aperture 318, the firstauxiliary aperture 320, and the second auxiliary aperture 322. The firstprimary aperture 314 may receive the fastener that couples theelectrical line 208 to the terminal 210 (e.g., via a ring lug) andestablishes an electrical connection between the electrical line 208 andthe terminal 210 (via a ring lug). The second primary aperture 316receives the fastener 308 extending through the aperture 306 in theblock 300 to couple the terminal 210 to the block 300. The third primaryaperture 318 receives the fastener 328 extending through the aperture330 in the fuse interface 214 to couple the fuse interface 214 to theterminal 210. The first and second auxiliary apertures 320, 322interface with the detents or protrusions 332 on the fuse interface 214to prevent the fuse interface 214 from rotating relative to the terminal210 and/or to key the fuse interface 214 into the desired position. Thefuse interfaces 214 shown in FIG. 8 are similar to the clip-type fuseinterfaces 214 for the 30 Amp fuse support block shown in FIG. 5. Thefuse interfaces 214 may include the slots 334 to interface with anannular lip of the fuse 206 to position the fuse 206 axially along anaxis of the fuse 206.

FIG. 9 is a perspective view of the 60 Amp fuse support block 204 ofFIG. 8 in the first configuration, without the fuse interfaces 214 shownfor the sake of clarity. As shown, the terminals 210 are coupled to themolding 218 via the second primary aperture 316 of each terminal 210.Each of the electrical lines 208 (not shown) couples to the respectiveterminal 210 via the first primary aperture 314. The fuse support block204 may be coupled to the housing 24 via fasteners extending through thefirst apertures 310 of the molding 218 and then engaging with thehousing 24. As was previously shown in and described with regard to FIG.3, when the fuse support block 204 is installed in the firstconfiguration, the electrical lines 208 (not shown) extend outward fromthe fuse support block 204, opposite the direction of the fuse block 202(not shown).

FIG. 10 is a perspective view of the 60 Amp fuse support block 204 inthe second configuration, without the fuse interfaces 214 shown for thesake of clarity. Unlike the first configuration shown in FIG. 9, thefuse support block 204 may be coupled to the housing 24 via fastenersextending through the second apertures 312 of the molding 218 and thenengaging with the housing 24. As was previously shown in and describedwith regard to FIG. 4, when the fuse support block 204 is installed inthe second configuration, the electrical lines 208 (not shown) couple tothe fuse support block 204 at the side that faces the fuse block 202(not shown), such that the electrical lines 208 (not shown) extend fromthe fuse support block 204 substantially outward toward the fuse block202, beneath the fuses 206, thus reducing the footprint of thedisconnect switch assembly 200 relative to the first configuration.

FIG. 11 is an exploded perspective view of a 100 Amp fuse support block204, which is an alternate embodiment of the 30 Amp fuse support blockshown in FIG. 5 and the 60 Amp fuse support block shown in FIG. 8. Aswith the 30 Amp and 60 Amp embodiments, the 100 Amp fuse support block204 includes the molding 218, three terminals 210, and three fuseinterfaces 214. However, rather than the clip-type fuse interfaces 214of the 30 Amp and 60 Amp fuse support blocks, the fuse interfaces 214 ofthe 100 Amp fuse support block are V-block type fuse interfaces 214.That is, the fuse interfaces 214 include a V-block 400 and a chuck 402.As shown, the V-block 400 includes a central channel 404, defined bywalls 406, that receives the chuck 402. One or both of the walls 406 mayinclude a protrusion or detent 408, which may assist in positioning thechuck 402 within the central channel 404. As shown, the V-block 400 mayalso include one or more apertures 410 for receiving a fastener 412 thatcouples the chuck 402 to the V-block 400 and/or that couples the V-block400 to the terminal 210. As with the clip-type fuse interfaces 214 shownin and described with regard to FIGS. 5 and 8, the V-blocks 400 mayinclude protrusions 332 or detents on an under side 414 of the V-block400 that may interface with the first and second auxiliary apertures320, 322 to position the fuse interface 214 upon the terminal 210. Inother embodiments, fasteners 412 extending through the apertures 410 inthe V-block 400 may be used to position the fuse interface 214 upon theterminal 210.

As shown in FIG. 11, the chuck 402 includes an aperture 416 or slotthrough which the fastener 412 extends when coupling the chuck 402 tothe V-block 400. Additionally, the chuck 402 may include a recess 418defined on one or both sides by a lip 420 to offset the chuck 402 fromthe V-block 400 and capture the respective fuse 206.

As shown in FIG. 11, the terminals 210 may be similar to the terminals210 shown in FIG. 8 in that the terminals 210 for the 100 Amp fusesupport block 204 do not include the notches 326 of the terminals forthe 30 Amp fuse support block shown in FIG. 5. Additionally, as with the60 Amp fuse support block 204, the 100 Amp fuse support block 204 doesnot include the connection points 222 of the 30 Amp fuse support blockshown in FIG. 5. Instead, as with the 60 Amp fuse support block 204, theelectrical lines 208 may couple directly to the terminals 210 via afastener and a ring lug. The molding 218 design for the 100 Amp fusesupport block may have slightly different dimensions than the moldings218 for the 30 Amp and 60 Amp fuse support blocks. However, the molding218 for the 100 Amp fuse support block 204 may still be made of a singlepart molded from a non-conductive material, such as a polymer. As withthe 30 Amp and 60 Amp fuse support blocks 204, the 100 Amp fuse supportblock 204 includes three terminals 210, one for each phase of power. Assuch, the molding includes the first, second, and third blocks 300,which are coupled to one another by the bridges 302 disposed between theblocks 300. Each of the blocks 300 may include the recess 304dimensioned to receive the respective terminal 210 and the aperture 306(e.g., through hole) through which the fastener 308 (e.g., bolt) mayextend to couple the terminal 210 to the block 300. Each of the bridges302 includes the first aperture 310 and the second aperture 312, whichmay be used to mount the fuse support block 204 to the housing in thefirst and second configurations, respectively.

As with the 30 Amp and 60 Amp fuse support blocks 204, each terminal 210includes the pattern of apertures to facilitate coupling the molding218, the fuse interface 214, and the electrical line 208 to the terminal210. As with the terminals 210 for the 30 Amp and 60 Amp fuse supportblocks 204, each of the terminals 210 for the 100 Amp fuse support block204 includes the first primary aperture 314, the second primary aperture316, the third primary aperture 318, the first auxiliary aperture 320,and the second auxiliary aperture 322. The first primary aperture 314may receive the fastener that couples the electrical line 208 to theterminal 210 (e.g., via the ring lug) and establishes an electricalconnection between the electrical line 208 and the terminal 210. Thesecond primary aperture 316 receives the fastener 308 extending throughthe aperture 306 in the block 300 to couple the terminal 210 to theblock 300. The third primary aperture 318 receives the fastener 328extending through the aperture 330 in the fuse interface 214 to couplethe fuse interface 214 to the terminal 210. The first and secondauxiliary apertures 320, 322 interface with the detents or protrusions332 on the fuse interface 214 to prevent the fuse interface 214 fromrotating relative to the terminal 210 and/or to key the fuse interface214 into the desired position.

FIG. 12 is a perspective view of the 100 Amp fuse support block 204 ofFIG. 11 in the first configuration, without the fuse interfaces 214shown for the sake of clarity. As shown, the terminals 210 are coupledto the molding 218 via the second primary aperture 316 of each terminal210. In some embodiments, each of the terminals 210 may include a step500, as shown in FIG. 12. Each of the electrical lines 208 (not shown)couples to the respective terminal 210 via first primary aperture 314and a ring lug. The fuse support block 204 may be coupled to the housing24 via fasteners extending through the first apertures 310 of themolding 218 and then engaging with the housing 24. As was previouslyshown in and described with regard to FIG. 3, when the fuse supportblock 204 is installed in the first configuration, the electrical lines208 (not shown) extend outward from the fuse support block 204, oppositethe direction of the fuse block 202 (not shown).

FIG. 13 is a perspective view of the 100 Amp fuse support block 204 inthe second configuration, without the fuse interfaces 214 shown for thesake of clarity. Unlike the first configuration shown in FIG. 12, thefuse support block 204 may be coupled to the housing 24 via fastenersextending through the second apertures 312 of the molding 218 and thenengaging with the housing 24. As was previously shown in and describedwith regard to FIG. 4, when the fuse support block 204 is installed inthe second configuration, the electrical lines 208 (not shown) couple tothe fuse support block 204 at the side that faces the fuse block 202(not shown) such that the electrical lines 208 (not shown) extend fromthe fuse support block 204 substantially outward toward the fuse block202, beneath the fuses 206, thus reducing the footprint of thedisconnect switch assembly 200 relative to the first configuration.

FIG. 14 is a flow chart of a process 600 for assembling and installingthe fuse support block 204 of the disconnect switch assembly 200. Thoughthe following discussion is directed to assembly and installation of thefuse support block 204 of the 30 Amp disconnect switch assembly 200depicted in FIGS. 3-7, it should be understood that similar techniquesmay be used for other embodiments of the fuse support block 204. Atblock 602, the terminals 210 are coupled to the molding 218. Aspreviously described, a fastener 308 may extend through apertures 306 inthe molding 218 and the terminals 210 in order to couple the terminals210 to the molding 218. In some embodiments, one of the apertures 306may include threads that engage with corresponding threads on thefastener 308 to hold the fastener 308 in place. In other embodiments, anut may be used to engage the threads of the fastener 308 to hold thefastener 308 in place.

At block 604, the fuse interfaces 214 are coupled to the terminals 210.As previously described, fasteners 308 may extend through correspondingapertures 306 in the fuse interfaces 214, the terminals 210, and in somecases the molding 218, to couple the fuse interfaces 214 to theterminals 210. Additionally, the protrusions 332 or detents of the fuseinterfaces 214 may engage with the corresponding apertures 320, 322 inthe terminals 210 to position the fuse interfaces 214 on the terminals210 and prevent movement of the fuse interfaces 214 after they areinstalled. As previously described, the fuse interfaces 214 may becoupled to the terminals 210 in one of two positions depending uponwhether the fuse support block 204 is to be installed in the firstposition or the second position. The fuse interfaces 214 may beclip-type fuse interfaces, V-block fuse interfaces, or some other typeof fuse interface.

At block 606, the fuse support block 204 is installed in the housing 24.To install the fuse support block 204 in the first configuration, thefirst set of apertures 310 may be aligned with corresponding aperturesof the housing 24, such that the first primary apertures 314 of theterminals 210 face away from the fuse block 202. Fasteners may extendthrough the apertures 310 and couple the fuse support block to thehousing 24. To install the fuse support block 204 in the secondconfiguration, the second set of apertures 312 should be aligned withcorresponding apertures of the housing 24, such that the first primaryapertures 314 of the terminals 210 face toward the fuse block 202.Fasteners may extend through the apertures 312 and couple the fusesupport block 204 to the housing 24.

At block 608, fuses 206 are installed in each of the respective sets offuse interfaces 214 disposed on the fuse block 202 and the fuse supportblock 204. At block 610, the electrical lines 208 may be coupled to therespective terminals 210 at the first primary apertures 314. In someembodiments (e.g., 30 Amp fuse support block 204), connection points 222and fasteners 324 may be used to connect the electrical lines 208 to theterminals 210. In other embodiments (e.g., 60 Amp and 100 Amp fusesupport blocks 204), ring lugs and fasteners may be used to connect theelectrical lines 208 to the terminals 210.

The disclosed techniques include a reversible fuse support block for adisconnect switch assembly that can be mounted in a first configurationhaving a normal-sized footprint, or a second configuration having areduced footprint. Specifically, the fuse support block includes amolding having two sets of mounting holes that allow the molding to beinstalled within the housing in two different positions (e.g., for firstconfiguration and second configuration). The fuse support block includesone or more terminals, each having a pattern of apertures, which mountto the molding. One or more fuse interfaces couple to respectiveterminals in two possible positions, a first position for the firstconfiguration, and a second position for the second configuration. Whenthe fuse interfaces are installed in the first position and the moldingis installed in the first position, the fuse interfaces are disposed insubstantially the same position relative to corresponding fuseinterfaces on a fuse support block as when the fuse interfaces areinstalled in the second position and the molding is installed in thesecond position. Accordingly, when the fuse support block is installedin the second position, electrical lines coupling the fuse support blockto the power source extend from the fuse support block underneath thefuses rather than extending outward from the side of the fuse supportblock opposite the fuses. Thus, the second configuration reduces thefootprint of the disconnect switch assembly relative to the firstconfiguration.

While only certain features of the present disclosure have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the embodiments describedherein.

The invention claimed is:
 1. A reversible fuse support block for aswitch disconnect assembly, comprising: a molding configured to beinstalled within a housing of the switch disconnect assembly in a firstposition and a second position, wherein the second position is rotated180 degrees relative to the first position; a terminal configured tocouple to the molding, wherein the terminal comprises a plurality ofapertures disposed in a pattern; and a first fuse interface configuredto receive a first end of a fuse, wherein the first fuse interface isconfigured to couple to the terminal in a first arrangement and a secondarrangement such that when the first fuse interface is installed in thefirst arrangement and the molding is installed in the first position,the first fuse interface is disposed in substantially the same positionrelative to a second fuse interface on a fuse block of the switchdisconnect assembly positioned within the housing, opposite the fusesupport block, as when the first fuse interface is installed in thesecond arrangement and the molding is installed in the second position.2. The reversible fuse support block of claim 1, wherein the fusesupport block is configured to receive an electrical line, wherein theelectrical line electrically couples the terminal to a power supply, andwherein the electrical line is coupled to the terminal via a ring lug.3. The reversible fuse support block of claim 2, wherein the disconnectswitch assembly is rated for 60 Amps.
 4. The reversible fuse supportblock of claim 1, wherein, when the molding is installed in the secondposition, an electrical line extends from the fuse support block towardthe fuse block, beneath the fuse extending between the fuse supportblock and the fuse block.
 5. A method of installing a fuse support blockfor a switch disconnect assembly, comprising: coupling a terminal to amolding, wherein the molding is configured to be installed within ahousing of the switch disconnect assembly in a first position and asecond position, and wherein the terminal comprises a plurality ofapertures disposed in a pattern; coupling a first fuse interface to theterminal, wherein the first fuse interface is configured to receive afirst end of a fuse, wherein the first fuse interface is configured tocouple to the terminal in a first arrangement and a second arrangementsuch that when the first fuse interface is installed in the firstarrangement and the molding is installed in the first position, thefirst fuse interface is disposed in substantially the same positionrelative to a second fuse interface on a fuse block of the switchdisconnect assembly positioned within the housing, opposite the fusesupport block, as when the first fuse interface is installed in thesecond arrangement and the molding is installed in the second position;and installing the molding in the housing.
 6. The method of claim 5,wherein the molding is installed in the first position.
 7. The method ofclaim 5, wherein the molding is installed in the second position.
 8. Themethod of claim 5, wherein the fuse support block is configured toreceive an electrical line, wherein the electrical line electricallycouples the terminal to a power supply, and wherein the electrical lineis coupled to the terminal via a ring lug.
 9. The method of claim 8,wherein the disconnect switch assembly is rated for 60 Amps.
 10. Anindustrial automation system, comprising: a power supply; an industrialautomation motor starter configured to receive power from the powersupply; a disconnect switch assembly configured to electrically couplethe power supply to the industrial automation motor starter, thedisconnect switch assembly comprising: a housing; a fuse block disposedwithin the housing, the fuse block comprising a first fuse interfaceconfigured to receive a first end of a fuse; a reversible fuse supportblock disposed within the housing, opposite the fuse block, thereversible fuse support block comprising: a molding configured to beinstalled within the housing in a first position and a second position,wherein the second position is rotated 180 degrees relative to the firstposition; a terminal configured to couple to the molding, wherein theterminal comprises a plurality of apertures disposed in a pattern; and asecond fuse interface configured to receive a second end of the fuse,wherein the second fuse interface is configured to couple to theterminal in a first arrangement and a second arrangement such that whenthe second fuse interface is installed in the first arrangement and themolding is installed in the first position, the second fuse interface isdisposed in substantially the same position relative to the first fuseinterface as when the second fuse interface is installed in the secondarrangement and the molding is installed in the second position.
 11. Theindustrial automation system of claim 10, comprising a fuse insulationcomponent disposed about the first fuse interface, the second fuseinterface, or both.
 12. The industrial automation system of claim 10,comprising an electrical line extending from the fuse support blocktoward the fuse block, beneath the fuse extending between the fusesupport block and the fuse block when the molding is installed in thesecond position.